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Hi
I'm Peter from Poland.
On the occasion of an event StarForce 2009 in Torun (Poland) I prepared the Swamp Trooper costume for my 6 years old son (photo - my avatar).
About six months ago I decided to make a Boba Fett costume for him. Parts of this costume (Gauntlets, Amor, Helmet, Jetpack, Blaster) are built of polystyrene, PVC (2-5mm) and aluminum (Gauntlet's rocket, knee darts, jetpack beacon). Of course, aluminium parts have been made on a lathe. I prepared the technical drawings with dimensions matched to the child . Work on this costume took me about 150 hours so far. I think I'm halfway through the project.
I would like to invite you to the forum of 501th Polish Garrison. There is a small "photostory" about my project. This is the page in Polish, but if you have questions I will try to answer.

A few photos of the current state of BF blaster.
Inside the barrel is a very strong flashlight LED.
Elements for stock (lying before the gun) has been cut by a laser plotter.
The entire length of the gun (with the stock) will be about 60cm (kid-size)

Hi Manuel !
I'm going to make silicone molds for the entire set (armour, jp, helmet, blaster, gauntlets, knees) and what won't be suitable for molding will be done with vaccu method.
I want to be in time with the complete costume for a convention in Legoland in Denmark 19 - 20 June 2010.
Perhaps we will meet there ?

Thanks a lot!
Of course I will be continuing my "photostory" on this forum (at the same time on the Polish 501th forum).

My first costume I build it was this Kashyyyk Trooper:
A helmet made of cardboard (2mm) + resin + filler & paint.
Helmet templates I found in network.
Armor was made in this way - "the image/photo->measure->cut from cardboard (also 2mm) + resin + filler & paint.
For shoulders straps and backpack I used parts of 2l bottles of coca cola.
Pokets and shin protectors was the parts of my old camo jacket.
I made all armour with helmet about 40 hours.

My god, piotr, your work is fantastic! Great progress bro! Will you make copies of that? My little son (3 years) has a boba fett costume and I need to update it in time ... pictures of your child armor and helmet in comparison with a normal sized armor would be great! Can you make some shots to compare it? or maybe give us some dimensions of the parts?

Thanks Manuel
Of course I will make copies of all parts of costume and blaster .
In october/november I'll start new project - Jango costume (including modifications of copies of my BF helmet and jetpack).)

The time has come to show the world the result of my work.
At the 2010 convention StarForce my son Milosz won the costume contest.
Functional "systems" in this costume:
- A working flamethrower (strong flashing LEDs)
- On the right sleeve two switches for a flashing beacon light on backpack, and chest display (LED)
- Flashing LEDs in the RF

In darkness Miłosz seems to be flashing Las Vegas

A little bit is still to be done. New ammo pouches, spats, , the ends of the axis of jp nozzles, attaching properly pieces of armor on the shoulders, complete painting backpack, broken jp stabilizerand right ear panel repair, set of shin tools, functionality of blaster and plates on blaster stock (ready for assembly).